Tonneau Cover Clamp Shim and Clamp Support

ABSTRACT

A clamp assembly for use with a tonneau cover assembly is provided. Illustratively, the clamp assembly may include a first clamp member, a second clamp member, a clamp fastener, and at least one shim. The second clamp member is located opposite the first clamp member to form a space located therebetween. The clamp fastener is extended through the space between the first clamp member and the second clamp member. The at least one shim is located in the space between the first clamp member and the second clamp member.

RELATED APPLICATIONS

The present Application relates to and claims priority to U.S.Provisional Patent Application, Ser. No. 63/154,215, filed on Feb. 26,2021, entitled “Tonneau Cover Clamp Shim and Clamp Support,” and U.S.Provisional Patent Application, Ser. No. 63/162,816, filed on Mar. 18,2021, entitled “Tonneau Cover Clamp Shim and Clamp Support—2. Thesubject matter disclosed in those Provisional Applications are herebyexpressly incorporated into the present Application in their entireties.

TECHNICAL FIELD AND SUMMARY

The present disclosure relates to tonneau cover assemblies for use onthe cargo box of a pickup truck and, particularly, to shims and clampsupports used in conjunction with a tonneau cover clamp to secure a railto the sidewall of the cargo box.

The sidewalls of certain pickup truck cargo boxes are made from multiplesheets of steel. In some instances, an outer wall of sheet metal formsthe exterior surface of the cargo box. That outer metal sheet istypically folded over to form the outer skin, top, and adownward-depending inner flange edge of the cargo box sidewall. A secondinner metal sheet is placed adjacent the outer sheet metal inside thecargo box. This inner metal sheet is likewise bent to form not only theinner sidewall, but also an inner top and flange edge, like the outermetal sheet. Lastly, there is often a plastic cap member that is placedand secured onto the top of the cargo box sidewall to form the topsurface of the sidewall. This cap also extends to form a top innerflange edge of the cargo box sidewall. The net result is that the innertop edge area of the cargo box is composed of two sheet metal flangesand one plastic cap flange edge. It is these flanges that a tonneaucover rail will clamp onto in order to secure to the cargo box sidewall.

When the cargo box is manufactured, however, these outer and inner metalsheets, that form the cargo box sidewall, top, and inner edge, have atolerance run out at that inner edge. This means that because the exactsize of each metal sheet may vary slightly, it is not a problem becausethe inner top edge of the cargo box sidewalls accommodates thoseslightly different sized metal sheets. For example, if the outer metalsheet is slightly oversized and the inner metal sheet is slightlyundersized, a space or gap is created between the flange edges of theinner and outer metal sheets at the top inner edge area of the sidewall.Depending on the size variation between the outer and inner metalsheets, the size of the gap may be relatively large or small.Presumably, if both sheets are properly sized, there will be no gapbetween the outer and inner sheets.

The same thing occurs between the outer metal sheet flange and top capflange. Depending on whether the outer metal sheet is slightlyundersized or oversized will determine the extent of a gap between theouter metal sheet flange and the top cap flange. Accordingly, multiplegaps may exist between these several flanges. Because the flanges aredownward-depending at the top inner sidewall of the cargo box, the gapsare not typically in view. One would have to look upward from underneaththe sidewall to see the gaps. As such, this design is an effective wayto manufacture a cargo box sidewall—except to the extent these flangesare used as a clamping structure for a tonneau cover rail clamp.

Inconsistent spacing that may occur between these inner and outer metalsheets (and plastic cap) creates a challenge for clamping a tonneaucover rail to the cargo box. Because these flanges extend downward (fromabout 12 mm to about half an inch) to form the inner edge area of thecargo box top sidewalls, and the gap between each flange varies fromtruck to truck, the rail clamp has a difficult time securing to thoseflanges. Indeed, depending on the spacing between the flanges, thetonneau cover clamp might not securely clamp onto the flanges at all.Rather, the clamps may be easily pried-off of the flanges about the axisof the rail.

An illustrative embodiment of the present disclosure provides a clampassembly for use with a tonneau cover assembly. The clamp assemblyincludes a clamp mount, a clamp back, a clamp fastener, and at least oneshim. The clamp back is located opposite the clamp mount to form a spacelocated therebetween. The clamp fastener is extended through the spacebetween the clamp mount and the clamp back. The clamp fastener couplesthe clamp mount to the clamp back. The at least one shim is located inthe space between the clamp mount and the clamp back and includes anopening located at a side and extends to a fastener slot. The clampfastener extends through the fastener slot in the at least one shim. Atleast a portion of the at least one shim is configured to fit betweenflanges of a cargo box sidewall.

In the above and further embodiments, the clamp assembly may furthercomprise: a cut out disposed through the at least one shim and extendsfrom the fastener slot; the cut out extends transverse from the fastenerslot; a second shim, wherein the second shim includes an opening locatedat a side and extends to a fastener slot in the second shim, wherein thesecond shim is located adjacent the at least one shim between the clampmount and the clamp back; the at least one shim has a first thicknessand the second shim has a second thickness, wherein the first thicknessis different than the second thickness; the first thickness of the atleast one shim is greater than the second thickness of the second shim;the first thickness of the at least one shim is less than the secondthickness of the second shim; a plurality of shims, wherein each of theplurality of shims includes an opening located at a side and extends toa fastener slot disposed through the each of the plurality of shims,wherein the plurality of shims is located between the clamp mount andthe clamp back; the at least one shim is a rectangular panel; and the atleast one shim has a uniform thickness.

Another illustrative embodiment of the present disclosure provides aclamp assembly for use with a tonneau cover assembly. The clamp assemblyincludes a first clamp member, a second clamp member, a clamp fastener,and at least one shim. The second clamp member is located opposite thefirst clamp member to form a space located therebetween. The clampfastener is extended through the space between the first clamp memberand the second clamp member. The at least one shim is located in thespace between the first clamp member and the second clamp member. The atleast one shim includes an opening located at a side and extends to afastener slot in the at least one shim. The clamp fastener extendsthrough the fastener slot in the at least one shim.

In the above and further embodiments, the clamp assembly may furthercomprise: a cut out disposed through the at least one shim and extendsfrom the fastener slot; the cut out extends transverse from the fastenerslot; a second shim, wherein the second shim includes an opening locatedat a side and extends to a fastener slot in the second shim, wherein thesecond shim is located adjacent the at least one shim between the firstclamp member and the second clamp member; the at least one shim has afirst thickness and the second shim has a second thickness, wherein thefirst thickness is different than the second thickness; the firstthickness of the at least one shim is greater than the second thicknessof the second shim; the first thickness of the at least one shim is lessthan the second thickness of the second shim; a plurality of shims,wherein each of the plurality of shims include an opening located at aside and extends to a fastener slot disposed through the each of theplurality of shims, wherein the each of the plurality of shims islocated between the first clamp member and the second clamp member; andthe at least one shim has a uniform thickness.

Another illustrative embodiment of the present disclosure provides aclamp assembly for use with a tonneau cover assembly. The clamp assemblyincludes a first clamp member, a second clamp member, a clamp fastener,and at least one shim. The second clamp member is located opposite thefirst clamp member to form a space located therebetween. The clampfastener is extended through the space between the first clamp memberand the second clamp member. The at least one shim is located in thespace between the first clamp member and the second clamp member. Atleast a portion of the at least one shim is configured to fit betweenflanges of a cargo box sidewall.

Additional features and advantages of the shims and clamp supportassemblies will become apparent to those skilled in the art uponconsideration of the following detailed descriptions exemplifyingembodiments of carrying out the shims and clamp support assemblies aspresently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The concepts described in the present disclosure are illustrated by wayof example and not by way of limitation in the accompanying figures. Forsimplicity, and clarity of illustration, elements illustrated in thefigures are not necessarily drawn to scale. For example, the dimensionsof some elements may be exaggerated relative to other elements forclarity. Further, where considered appropriate, reference labels may berepeated among the figures to indicate corresponding or analogouselements.

FIG. 1 is a perspective view of a cargo box;

FIG. 2 is a cross-sectional view of a sidewall portion of the cargo box;

FIG. 3 is a detail perspective view of a portion of the cargo boxsidewall along with a portion of a rail and a clamp;

FIG. 4 is another detail perspective view of a portion of the cargo boxsidewall with the portion of the rail and clamp;

FIG. 5 is a side detail view of a portion of the cargo box sidewall,rail, and clamp;

FIG. 6 is a detail perspective view of a portion of a cargo boxsidewall, rail, and clamp assembly, along with shims in exploded view;

FIG. 7 is another detail perspective view of a portion of a cargo boxsidewall, rail, and clamp with shims positioned between flanges of thecargo box sidewall;

FIG. 8 is an end sectional detail view of a portion of a cargo boxsidewall with a rail, clamping assembly, and shims located betweenflanges of the cargo box sidewall;

FIG. 9 is an end sectional detail view of a portion of a cargo boxsidewall with shims located between flanges of the cargo box sidewall;

FIG. 10 is an end sectional detail view of a portion of the cargo boxsidewall, including multiple shim arrangements in exploded view;

FIG. 11 is an end sectional detail view of a cargo box sidewall withshims located between flanges of the cargo box sidewall and additionalmultiple shim arrangements in exploded view;

FIG. 12 is an end sectional view of a portion of a cargo box sidewall inaddition to multiple shim arrangements shown in exploded view;

FIG. 13 is an end sectional detail view of a portion of a cargo boxsidewall with a shim arrangement located between flanges, as well asother shim arrangements shown in exploded view;

FIG. 14 is an end sectional detail view of a portion of a cargo boxsidewall with multiple shim arrangements shown in exploded view;

FIG. 15 is an end sectional detail view of a portion of a cargo boxsidewall with a shim arrangement installed between flanges andadditional shim arrangements shown in exploded view;

FIG. 16 is a perspective view of a shim;

FIG. 17 is a perspective sectional detail view of a portion of a cargobox sidewall with a rail coupled thereto by a clamp assembly;

FIG. 18 is a detail facing view of a portion of a cargo box sidewallwith a shim hung on a clamp fastener from a clamp assembly;

FIG. 19 is another detail facing view of a portion of a cargo boxsidewall with a shim hung on a clamp fastener from a clamp assembly;

FIG. 20 is a perspective detail view of a portion of a cargo boxsidewall, along with a portion of a rail and a clamp assembly, as wellas an illustrative embodiment of a clamp bracket assembly;

FIG. 21 is an end sectional detail view of a portion of a cargo boxsidewall that includes a clamp, rail, and clamp bracket assembly;

FIG. 22 is a sectional detail view of a portion of a cargo box sidewallwith the rail, clamp assembly, and clamp bracket assembly, wherein theclamp bracket assembly is shown in exploded view; and

FIG. 23 is an upward-looking underside detail sectional perspective viewof a portion of a cargo box sidewall with a portion of a rail attachedthereto via a clamp assembly and showing a clamp bracket assembly.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplification set out hereinillustrates embodiments of the shims and clamp support assemblies andsuch exemplification is not to be construed as limiting the scope of theshims and clamp support assemblies in any manner.

DETAIL DESCRIPTION OF THE DRAWINGS

The figures and descriptions provided herein may have been simplified toillustrate aspects that are relevant for a clear understanding of theherein described devices, systems, and methods, while eliminating, forthe purpose of clarity, other aspects that may be found in typicaldevices, systems, and methods. Those of ordinary skill may recognizethat other elements and/or operations may be desirable and/or necessaryto implement the devices, systems, and methods described herein. Becausesuch elements and operations are well known in the art, and because theydo not facilitate a better understanding of the present disclosure, adiscussion of such elements and operations may not be provided herein.However, the present disclosure is deemed to inherently include all suchelements, variations, and modifications to the described aspects thatwould be known to those of ordinary skill in the art.

Accordingly, an illustrative embodiment of the present disclosureprovides at least one shim, or a plurality of shims, as needed, to beplaced between either one or both of the gaps between the flanges. Byfilling the gaps with one or more shims, a solid structure is formedthat the clamp is able to clamp onto. The shims may further have alength extending from the clamp jaws to the clamping fastener. Theclamping fastener may assist holding the shim or shims in place. In someinstances the clamping fastener may act as a lever to push the shimsupward while the clamp is being secured. Furthermore, the clamp may beengageable with the clamp screw to inhibit rotation of the shim or shimswhile the clamping fastener is rotating to secure the clamping jaws tothe flanges of the cargo box sidewall. This assists in ease ofinstallation.

Another illustrative embodiment of the present disclosure provides analternate solution for preventing the clamp from rotating out about theaxis of the rail when securing to the cargo box sidewall. In thisembodiment, a support bracket is illustratively attached to both theinner sidewall sheet of the cargo box and to the clamp. By fixing thebracket at these two points, the clamp is prevented from rotating aboutthe rail, and thus, prying off same.

A perspective view of a cargo box 2 is shown and FIG. 1. This cargo box2 includes a bulkhead panel 4, tailgate 6, and sidewalls 8 and 10. Someversions of the sidewalls, such as sidewalls 8 and 10 shown here, aremade from inner and outer skins or sheets of metal such as steel. Forcargo box 2, each of sidewalls 8 and 10 are composed of an outer sheet12 and inner sheet 14 (see also FIG. 2). Additionally, sidewalls 8 and10 may further include a sidewall cap 16 that serves as the top surfaceof the sidewalls.

To further illustrate, a cross-sectional view of sidewall 10 is shown inFIG. 2. Here, outer sheet 12 is shown to form the outer surface ofsidewall 10. Outer sheet 12 is also bent at 18 to form a top surface 20and then bent again at 22 terminating at outer sheet flange 24.Likewise, inner sheet 14 forms the inner surface of sidewall 10. Innersheet 14 also bends at 26 forming its own top surface 28 then bendsagain at 30 to form an inner sheet flange 32. This configuration ofouter sheet 12 and inner sheet 14 terminate at flanges 24 and 32. Thisprovides both a top structure for sidewall cap 16 to attach to, as wellas a tolerance run out for inner and outer sheets 12 and 14,respectively.

With respect to the latter, it is understood that such cargo boxes, suchas cargo box 2, is mass-produced. This means many outer sheets 12 andinner sheets 14 are manufactured at a time and then assembled to formmany sidewalls 10. It is contemplated that manufacturing several outersheets 12 (as well as inner sheets 14) may create small differences insize between each sheet manufactured. Thus, during manufacture of outersheet 12, there may be slight differences in size between each outersheet 12. Similarly, during manufacture of each inner sheet 14, theremay be slight differences in size between each inner sheet 14. At leastpart of the reason for having top surfaces 26 and 28, as well as flanges24 and 32, is to accommodate those small variations in size of sheets 12and 14, respectively. As a consequence, a tolerance run out or gap 34 iscreated between flanges 24 and 32. There may also be a tolerance run outor gap 36 located between flange 24 of outer sheet 12 and a flange 38that is part of and depends from sidewall cap 16. It is contemplated,for example, that between different cargo boxes 2, gap 34 may be wideror narrower from this cross sectional perspective depending on theultimate sizes of outer sheet 12 and inner sheet 14. Likewise, there maybe a wider or narrower gap 36 between flanges 24 and 38 for similarreasons. For cargo box sidewalls 8 or 10 on any particular pickup truck,it will not be known how wide or narrow either gaps 34 or 36 will be.

A rail for a tonneau cover is attached to flanges 32 and 38 (sandwichingflange 24). Having such gaps as 34 and 36 make it difficult for the railto secure onto the sidewall. As shown in the detail perspective view ofa portion of sidewall 10 in FIG. 3, for example, a rail 40 with lipplate 42 sets onto sidewall cap 16 with a clamp bracket 44illustratively depending downwardly adjacent flange 38. It isappreciated that rail 40 is longitudinally extending along the side ofsidewall 10. Illustrative cover rails and clamps related to the typedisclosed herein may be found in U.S. patent application Ser. No.16/101,900, entitled “Tonneau Cover” filed on Aug. 13, 2018, and U.S.patent application Ser. No. 16/928,117, entitled “Multi-Panel TonneauCover” filed on Jul. 14, 2020, the disclosures of which are hereinincorporated by reference in their entireties. It is appreciated thatother tonneau cover rails and clamps of differing configurations may besecured onto sidewalls 8 and 10 using structures from this disclosureand are, thus, contemplated to be within the scope of this disclosure.It is further appreciated, that the discussion and descriptions relatedto sidewall 10 apply equally to sidewall 8 in mirror image and viceversa.

As particularly shown herein, a clamp assembly 46 is in the process ofbeing attached to clamp slot 48. Clamp assembly 46 includes a clampmount 50 having an upward-extending flange 52 that fits into clamp slot48 of rail 40. Clamp mount 50 also includes a planar surface 54 thatrests on support 56 of rail 40. Opposite clamp mount 50 is clamp back 58coupled together via clamping fastener 60, which extends therebetween.An illustrative serrated-type gripping surface 62, on clamp back 58, isintended to abut flange 32 when clamping fastener 60 is rotated. Thisconfiguration will draw clamp mount 50 and clamp back 58 toward eachother. An adjustment screw 64 is disposed through clamp base 66 toengage clamp back base 68 for moving clamp back 58 vertically as needed.This allows clamp assembly 46 to accommodate down-turned flanges ofdifferent character on different types of truck bed sidewalls. It isappreciated that clamping fastener 60 may be disposed through a slot 70which is disposed through clamp mount 50 so clamp back 58 can be movedvertically. It is further appreciated that rail 40 extends along alongitudinal axis 72 about which clamp assembly 46 rotates in directions74 and 76 to remove from or engage with clamp bracket 44.

Another detail perspective view of a portion of sidewall 10 is shown inFIG. 4. Here, clamp assembly 46 has been rotated in direction 76 soflange 52 of clamp mount 50 fits into clamp slot 48 of clamp bracket 44.Also depicted here is clamp back 58 in position so that gripping surface62 will engage inner sheet flange 32 when clamping fastener 60 pullsclamp back 58 in direction 78 to a clamping position. Longitudinal axis72 of rail 40 is also shown in this view. In order to secure rail 40onto sidewall 10, clamp assembly 46 needs to clamp rail 40 againstsidewall cap flange 38 of sidewall cap 16 and inner sheet flange 32 withouter sheet flange 24 sandwiched therebetween. It will be appreciated bythe skilled artisan upon reading this disclosure that the same clamp andrail assembly may be employed on sidewall 8 as described herein withsidewall 10.

A side detail view of a portion of sidewall 10 with rail 40 set ontosidewall cap 16 and clamp assembly 46 clamping against inner sheetflange 32 is shown in FIG. 5. Here, clamping fastener 60 has drawn clampback 58 in direction 78 to create the clamping force. A problem,however, is that gap 34 between flanges 32 and 24, as well as gap 36between flange 24 and flange 38 create space between flanges 32 and 38that allow same to move thereby preventing a secure clamping betweengripping surface 62 and clamp bracket 44. As clamping fastener 60 drawsclamp mount 50 in direction 80 and clamp back 58 in direction 78,gripping surface 62 of clamp back 58 will tend to push flange 32 indirection 78 as well, thereby preventing a secure clamping between rail40 and sidewall 10. This means that clamp assembly 46 might be easilypried from clamp slot 48 of clamp bracket 44 by pulling in direction 74.It is also conceivable that vibration during movement of the pickuptruck may also loosen clamp assembly 46 causing same to disengage fromsidewall 10.

Another detail perspective view of a portion of sidewall 10 is shown inFIG. 6. This view is similar to that shown in FIG. 4 with clamp assembly46 having been rotated in direction 76 so upward extending flange 52 ofclamp mount 50 fits into clamp slot 48 of clamp bracket 44. Clamp back58 is also in position so that gripping surface 62 will engage innersheet flange 32 when clamping fastener 60 pulls clamp back 58 indirection 78 to a clamping position. Further in this view, however, area plurality of shims 82 and 84 configured to be fitted in gap 86 betweenclamp mount 50 and clamp back 58, as well as in gaps 34 and 36 (see,also, FIG. 5). The purpose of shims 82 and 84 are to provide a solidsurface between flange 32 and flange 38 that clamp assembly 46 may clamponto. Shims 82 and 84 may have a length extending to clamping fastener60 to assist with holding shims 82 and 84 in place during installationof clamp assembly 46. Clamping fastener 60 may also act as a lever topush the shims upward while clamp assembly 46 is being secured. In theillustrated embodiment, each of shims 82 and 84 may include a fastenerslot 88 and a cut out 90 in communication with fastener slot 88.

As shown in the detail perspective view of a portion of sidewall 10 inFIG. 7, shims 82 and 84 are positioned within gap 86 between clamp mount50 and clamp back 58. Shims 82 and 84 are also positioned between flange32 and flange 38 to fill gaps 34 and 36 (see, also, FIG. 8). This,again, provides a solid clamping body between flange 32 and flange 38.Also depicted is clamping fastener 60 disposed in cut out 90 of shims 82and 84. Having shims extend to clamping fastener 60 extends the lengthof the clamping body between flange 32 and flange 38, as well asproviding a position certain within gap 86 so shims 82 and 84 positionproperly between flange 32 and 38, which helps in the ease ofinstallation.

An end sectional detail view of a portion of sidewall 10 with clampassembly 46 clamping rail 40 against flange 38 and flange 32 is shown inFIG. 8. This view shows shim 82 and shim 84 located within gap 34between flange 32 and flange 24. It is appreciated that shims 82 and 84effectively fill gap 34 to provide solid body between the flanges.Similarly, a second shim 84 is fitted in gap 36 between flange 24 andflange 38. The combination of the three shims 82, 84, and 84, fill gaps34 and 36 to create an effectively solid clamping body between flange 32and flange 38. Having this solid structure better enables clamp assembly46 to clamp onto sidewall 10. As shown, gripping surface 62 may abutboth flange 32 and portion of shim 82. It is, thus, appreciated, thathow the length of shims 82 and 84 may serve to enhance the clampabilityof clamp assembly 46.

It is further appreciated, that shim 82 has a wider thickness T thanthickness T′ of shim 84. Because the gap sizes or widths of gap 34 andgap 36 may vary because of the tolerance running between outer sheet 12and inner sheet 14 it will not be known from the outset what thethickness of gap 34 or gap 36 will be that needs filling. Having shimsof varying thicknesses, using a combination of same in the gaps, willserve to close same and provide a clampable body or structure. In thecase shown here in FIG. 8, the combination of shim 82 with shim 84provides enough thickness to fill gap 34. In contrast, for gap 36, onlya single shim 84 is needed to fill this gap. It is appreciated that anycombination and number of such shims may be employed in order to fillgaps 34 and 36 (see, also FIGS. 10 through 15).

This view further depicts clamping fastener 60 disposed through shims 82and 84 in addition to clamp mount 50 and clamp back 58. It isappreciated that clamping fastener 60 supports shims 82 and 84 to keepthem in place. Particularly, by placing clamping fastener 60 in cut out90, shims 82 and 84 may be held in a generally vertical orientation.Even further, clamping fastener 60 may be used to apply a lever forcegenerally in direction 92 to keep shims 82 and 84 about vertically inplace within gaps 34 and 36. Also, while in place about clampingfastener 60, shims 82 and 84 have less propensity to move horizontally.Because fastener slot 88 is open at one end, shims 82 and 84 can be slidover clamping fastener 60 and into place between gaps as needed. This isuseful when assembling rail 40 onto sidewall cap 16. With clamp assembly46 in place, either or both shims 82 and/or 84 may be slid horizontallyover clamping fastener 60 through fastener slot 88. This process can berepeated with multiple shims 82 and/or 84 as needed to fill gaps 34 and36 to create the necessary structure with which clamp assembly 46 mayclamp to.

Another end sectional detail view of a portion of sidewall 10 is shownin FIG. 9. Substantively, this view is similar to that shown in FIG. 8except with rail 40 and clamp assembly 46 removed. In this view, it isfurther appreciated how shims 82 and 84 can fill gaps 34 and 36 betweenflanges 32, 24, and 38 to create a clampable structure. Between flange32 and flange 38 there is no longer gaps that allow these flanges tomove if a force is applied to them. Furthermore, the solid bodies ofshims 82 and 84 extend further downward in direction 94 to essentiallyextend the clamping body for clamp assembly 46. This occurs while at thesame time clamp assembly 46, illustratively, via clamping fastener 60,serves to support shims 82 and 84.

It will be appreciated by the skilled artisan upon reading thisdisclosure that because it is unknown what the gap size will be for gaps34 and 36, multiple combinations of shim sets may be employed to fillthose gaps regardless of their widths. As shown in this end sectionaldetail view of a portion of sidewall 10 in FIG. 10, with W of gap 34between flanges 32 and 24, as well as width W′ of gap 36 between flanges24 and 38, are relatively large. This means that clamp assembly 46 maynot be able to grip flange 32 and hold rail 40 in place. That said, anycombination of shims 82 and 84 having thicknesses T and T′,respectively, that, when combined, generally match the widths W and W′of gaps 34 and 36, respectively, can be employed. In this particularinstance, as shown in the end sectional detailed view of a portion ofsidewall 10, similar to that shown in FIG. 10, now shown in FIG. 11,shims 82 and 84 are inserted into gap 34 while shim 84 alone is fittedinto gap 36. This fills the space between flanges 32 and 38, providingan essentially solid structure with which clamp assembly 46 may clamponto. It will be further appreciated that due to the varying potentialwidths of gaps 34 and 36, it may take trial and error to determine howmany of either/or shims 82 and/or 84 are needed to fill the particulargap or gaps.

As further example, as shown in this end sectional detailed view of aportion of sidewall 10 of FIG. 12, gaps 34 and 36 exist between flanges32 and 24, as well as flanges 24 and 38. In this case, however, whencomparing to gaps 34 and 36 from FIG. 10, now gap 34 has a width W″which is narrower than with width W. Given this smaller size, it willneed to be decided which shim or combination of shims 82 and/or 84 maybe used to fill gap 34. As also shown in this view, various combinationsof shims 82 and 84 may be employed to fill the gaps of different widths.In this example, however, despite gap 34 having a narrower width W″, gap36 still has a width W′ similar to that shown in FIG. 10.

The end sectional detailed view of a portion of sidewall 10 shown inFIG. 13 depicts a shim 84 fitted into gap 34 to fill same having a widthW″ (see, FIG. 12), as well as another shim 84 to fit into gap 36, suchas was done previously, as shown in FIGS. 10 and 11. In this case,because of the narrow widths only a single thinner shim 84 is needed tocreate a solid structure between flange 32 and flange 38. With gaps 34and 36 now filled, clamp assembly 46 has a solid structure with which toclamp onto.

In still a further example, as shown in the end sectional detail view ofa portion of sidewall 10 of FIG. 14, gap 34, located between flange 32and flange 24, is coincidently even wider than width W from FIG. 10.Width W′″ of gap 34, shown in FIG. 14, may therefore require more shimsof shims 82 or 84, in order to create a solid structure. It may requiretrial and error, possibly one shim 82, as well as two thinner shims 84,or possibly two thicker shims 82 and one thinner shim 84, to be able tofill gap 34.

As is shown in the end sectional detail view of a portion of sidewall 10of FIG. 15, it ends up being one thicker shim 82 with two thinner shims84 that are necessary to fill gap 34 between flange 32 and flange 24.Again, it will be appreciated by the skilled artisan upon reading thisdisclosure that because it will not necessarily be known how wide thegaps 34 and 36 will be, trial and error by trying multiple shims ofvarying thicknesses to fill gaps 34 and 36. It is notable in FIGS. 14and 15 that there is no gap 36. Flange 24 essentially abuts flange 38,leaving no gap 36 requiring to be filled. When there is no such gap, allthat is needed is to use whatever combination of shims 82 and/or 84 thatwill fill gap 34 to provide a solid structure between flange 32 andflange 38 so that clamp assembly 46 may be able to clamp onto thesidewall.

A perspective view of shim 82 is shown in FIG. 16. It is appreciatedthat shims 82 and 84 may have the same profile but differentthicknesses. Shim 82, as shown here, has a thickness T whereas, shim 84may have a thinner thickness T′ (see, FIG. 8). As shown herein, shim 82includes a facing surface 95 size to abut up against other shims or theflanges as previously discussed. A slot opening 96 is disposed throughan outer periphery of shim 82, leading to fastener slot 88 and cut out90. In the illustrative embodiment, slot opening 96 is located at theside of shim 82 so that same can be slid sideways into gap 86, betweenclamp mount 50 and clamp back 58 (see, FIG. 7). While clamp assembly 46is hanging on clamp slot 48 of rail 40 prior to tightening clampassembly 46, shim 82 (and/or shim 84) may be slid into gap 86, such thatclamping fastener 60 may be disposed into fastener slot 88 through slotopening 96, and set into cut out 90. The shim 82 (and/or 84) may hang onclamping fastener 60 at cut out 90, while determining whether additionalor alternate shims are needed to be placed in gaps 34 and/or 36. Inother words, cut out 90 assists in keeping the shim in place during theinstallation process of rail 40.

A perspective sectional detail view of the portion of sidewall 8 withrail 40 coupled thereto with clamp assembly 46 is shown in FIG. 17. Thisview shows outer sheet 12 and inner sheet 14 forming flanges 24 and 32,respectively. Sidewall cap 16 is also shown forming flange 38. Gaps 34and 36 are shown located between flanges 32 and 24, as well as flanges24 and 38, respectively. To accommodate for those gaps 34 and 36, shims82 and 84 are placed within gap 86 between clamp mount 50 and clamp back58. This view demonstrates how clamping fastener 60 is disposed withinfastener slots 88 of all shims 82 and 84 and seated within cut out 90,also disposed in all of shims 82 and 84. With shims 82 and 84 seated onclamping fastener 60 within gap 86 they are likewise positioned to fillgaps 34 and 36, such as that shown in FIG. 8. If it happens that gaps 34and 36 were not filled by the shown configuration of shims 82 and 84,one or more of shims 82 and/or 84 may be removed by pulling it fromclamping fastener 60 through slot 88 to be replaced by a different shimvia the same process.

Another illustrative embodiment with respect to shims 82 and 84 aretheir polygonal shape. A detail facing view of the portion of sidewall10 that shows shim 82 hung on clamping fastener 60 at cut out 90 isshown in FIGS. 18 and 19. With respect to FIG. 18, shim 82 is locatedadjacent clamp back 58, as well as flange 32. An issue that such clampshave when they are being tightened via a rotating fastener, such asclamping fastener 60, is that the clamps may be urged to rotate as well.Because shim 82 (and/or shim 84) is sitting on clamping fastener 60 atcut out 90, there is potential that such contact may urge the shim torotate, such as in direction 98 as shown in FIG. 19. If shim 82 (and/orshim 84) rotates in direction 98 as clamping fastener 60 also rotates indirection 98, corner 100 of shim 82 (and/or shim 84) will abut theunderside of top surface 20 of outer sheet 12. This will limit rotationof shim 82 (and/shim 84). By limiting this rotation, the shim will notbe rotated out of its positioning between the sidewall flanges, therebystaying in place sufficiently to provide the structure needed for clampassembly 46. It is appreciated that such shim corners such as corner 100may exist on opposing sides of shim 82 (and/or shim 84), such that itcan be prevented from rotating in the opposite direction if need be.Limiting the shim's ability to rotate while tightening clamp assembly 46further aids in the ease of adding shims to same.

Another illustrative embodiment of the present disclosure provides asupport bracket that selectively attaches to the clamp assembly and thecargo box to prevent the clamp assembly from rotating about the railbecause of the same construction issues previously described. Aperspective detail view of a portion of sidewall 8 composed of outersheet 12 and inner sheet 14 along with sidewall cap 16 is shown in FIG.20. Additionally, rail 40 from a tonneau cover assembly is placed onsidewall cap 16. Clamp assembly 46 is also shown fitted into clamp slot48 of clamp bracket 44 on rail 40. A distinction here, however, is thata clamp bracket assembly 110 is shown fixed to both clamp assembly 46and inner sheet 14. A typical feature with inner sheets (such as innersheet 14) of pickup truck sidewalls is they have holes disposedtherethrough at various locations along sidewall 8 (or sidewall 10). Avariety of reasons may exist for having these holes, particularly ininner sheet 14. But because these holes are a relatively commonoccurrence they can be employed to hold a clamp assembly so it bettersecures the rail onto the cargo box sidewall. This can be particularlyuseful in circumstances where the inner flanges of the steel sheets thatformed the sidewall have gaps between them for tolerance run out aspreviously described.

As is appreciated in this view, clamp bracket assembly holds clampassembly 46 so it cannot pivot about longitudinal axis 72 that extendsgenerally along the length of rail 40. As illustratively shown, clampbracket assembly 110 includes a bracket member 112 extending fromsurface 114 of inner sheet 14. A fastener 116 is disposed through innersheet 14 and bracket member 112 to secure same to inner sheet 14.Bracket member 112 extends to clamp base 66 of clamp mount 50 andattaching thereto for limiting movement of clamp mount 50. It isappreciated that clamp back 58 secures to clamp mount 50 via clampingfastener 60 as previously described in prior embodiments. It will beappreciated by the skilled artisan upon reading this disclosure thatbracket member 112 being fixed at a point on sidewall 8 and to clampassembly 46 limits movement of same.

Also shown here is adjustment screw 64 that can receive nut 118 whichassists in securing bracket member 112 to clamp base 66. In particular,bracket member 112 may include a hole 124 disposed therethrough (see,FIG. 22) that receives adjustment screw 64, which is otherwise astandard feature on this particular clamp assembly 46 independent ofclamp bracket assembly 110. This illustrative configuration securesbracket member 112 to clamp assembly 46. With respect to disclosure ofclamp bracket assembly 110 herein relative to sidewall 8, it isappreciated that such clamp bracket assembly 110 may be used in the sameway on sidewall 10. Additionally, clamp bracket assembly 110 may be usedat various locations along rail 40 as needed and/or as holes are eithermade or available through inner sheet 14.

An end sectional detail view of a portion of sidewall 8, including outersheet 12, inner sheet 14, and sidewall cap 16 is shown in FIG. 21.Depicted is clamp assembly 46 clamping rail 40 to sidewall 8.Particularly, gripping surface 62 of clamp back 58 engages flange 32 ofinner sheet 14 while upward extending flange 52 of clamp mount 50 isfitted into clamp slot 48 in rail 40 to hold same against flange 38 ofsidewall cap 16. When clamping fastener 60 is rotated, clamp mount 50and clamp back 58 are drawn together to clamp rail 40 onto sidewall 8 asshown. Adjustment screw 64 may be rotated to raise and lower clamp back58 with respect to clamp mount 50 so gripping surface 62 can bepositioned against flange 32. As previously discussed, however, becauseof gaps between flanges such as gap 34 as previously discussed, thisclamping arrangement alone may result in clamp assembly 46 being able tobe pried out away from flange 32 and clamp slot 48. By employing clampbracket assembly 110, however, clamp assembly 46 is not pivotable indirections 74 or 76 that may otherwise pry clamp assembly 46 fromsidewall 8.

This view shows bracket member 112 fastened to both inner sheet 14 viafastener 116 and to clamp base 66 via adjustment screw 64 with nut 118.In this illustrative embodiment, a bushing 120 may be disposed through ahole 122 (see, FIG. 22) in inner sheet 14 and through surface 114 toreceive fastener 116. Again, having bracket member 112 extending betweensidewall 8 and clamp assembly 46 and secured at those locations, clampassembly 46 cannot rotate in direction 74 and, thus, pry out of clampslot 48 of rail 40.

A sectional detail exploded view of a portion of sidewall 8 with rail40, clamp assembly 46, and clamp bracket assembly 110 is shown in FIG.22. This view further depicts the illustrative components of clampbracket assembly 110. For instance, bracket member 112 is shownincluding hole 124 at one side that allows receipt of adjustment screw64 that threadedly secures to clamp base 66 with nut 118 andillustrative lock washer 126. Illustratively, another side of bracketmember 112 may be bent transversely, as needed, so that bore 128 may bedisposed therethrough in order to receive fastener 116. Illustratively,a washer 130 may optionally be used between fastener 116 and bore 128.Bushing 120 may be sized to have an outer periphery that friction fitsor otherwise attaches to hole 122 disposed through inner sheet 14. Abore 132 disposed through bushing 120 receives fastener 116 so as tosecure bracket member 112 against surface 114 of inner sheet 14.

An upward-looking underside detail sectional perspective view ofsidewall 8 with rail 40 attached thereto via clamp assembly 146 is shownin FIG. 23. This view further shows bracket member 112 attached at clampbase 66 of clamp mounts 50 via adjustment screw 64 and nut 118. It isappreciated how bracket member 112 extends from surface 114 of innersheet 14 to hold clamp assembly 46 in place. It is appreciated thatbracket member 112 may include an additional bore 134 to provide theinstaller options to insert fastener 116 for purposes of aligningbracket member 112 with a hole disposed through inner sheet 14.Furthermore, one or more sides or portions of bracket member 112 may bebent transverse so as also to accommodate holes at various locations oninner sheet 14.

In the drawings, some structural or method features may be shown inspecific arrangements and/or orderings. However, it should beappreciated that such specific arrangements and/or orderings may not berequired. Rather, in some embodiments, such features may be arranged ina different manner and/or order than shown in the illustrative figures.Additionally, the inclusion of a structural or method feature in aparticular figure is not meant to imply that such feature is required inall embodiments and, in some embodiments, may not be included or may becombined with other features. It should also be appreciated that, to theextent any subject matter disclosed in this non-provisional patentdocument conflicts with the priority application, the disclosure fromthis non-provisional patent document controls.

What is claimed:
 1. A clamp assembly for use with a tonneau coverassembly, the clamp assembly comprising: a clamp mount; a clamp backlocated opposite the clamp mount to form a space located therebetween; aclamp fastener extended through the space between the clamp mount andthe clamp back; wherein the clamp fastener couples the clamp mount tothe clamp back; and at least one shim located in the space between theclamp mount and the clamp back; wherein the at least on shim includes anopening located at a side and extends to a fastener slot in the at leastone shim; wherein the clamp fastener extends through the fastener slotin the at least one shim; and wherein at least a portion of the at leastone shim is configured to fit between flanges of a cargo box sidewall.2. The clamp assembly of claim 1, further comprising a cut out disposedthrough the at least one shim and extends from the fastener slot.
 3. Theclamp assembly of claim 2, wherein the cut out extends transverse fromthe fastener slot.
 4. The clamp assembly of claim 1, further comprisinga second shim, wherein the second shim includes an opening located at aside and extends to a fastener slot in the second shim, wherein thesecond shim is located adjacent the at least one shim between the clampmount and the clamp back.
 5. The clamp assembly of claim 4, wherein theat least one shim has a first thickness and the second shim has a secondthickness, wherein the first thickness is different than the secondthickness.
 6. The clamp assembly of claim 5, wherein the first thicknessof the at least one shim is greater than the second thickness of thesecond shim.
 7. The clamp assembly of claim 5, wherein the firstthickness of the at least one shim is less than the second thickness ofthe second shim.
 8. The clamp assembly of claim 1, further comprising aplurality of shims, wherein each of the plurality of shims includes anopening located at a side and extends to a fastener slot disposedthrough the each of the plurality of shims, wherein the plurality ofshims is located between the clamp mount and the clamp back.
 9. Theclamp assembly of claim 1, wherein the at least one shim is arectangular panel.
 10. The clamp assembly of claim 1, wherein the atleast one shim has a uniform thickness.
 11. A clamp assembly for usewith a tonneau cover assembly, the clamp assembly comprising: a firstclamp member; a second clamp member located opposite the first clampmember to form a space located therebetween; a clamp fastener extendedthrough the space between the first clamp member and the second clampmember; and at least one shim located in the space between the firstclamp member and the second clamp member; wherein the at least one shimincludes an opening located at a side and extends to a fastener slot inthe at least one shim; wherein the clamp fastener extends through thefastener slot in the at least one shim.
 12. The clamp assembly of claim11, further comprising a cut out disposed through the at least one shimand extends from the fastener slot.
 13. The clamp assembly of claim 12,wherein the cut out extends transverse from the fastener slot.
 14. Theclamp assembly of claim 11, further comprising a second shim, whereinthe second shim includes an opening located at a side and extends to afastener slot in the second shim, wherein the second shim is locatedadjacent the at least one shim between the first clamp member and thesecond clamp member.
 15. The clamp assembly of claim 14, wherein the atleast one shim has a first thickness and the second shim has a secondthickness, wherein the first thickness is different than the secondthickness.
 16. The clamp assembly of claim 15, wherein the firstthickness of the at least one shim is greater than the second thicknessof the second shim.
 17. The clamp assembly of claim 15, wherein thefirst thickness of the at least one shim is less than the secondthickness of the second shim.
 18. The clamp assembly of claim 11,further comprising a plurality of shims, wherein each of the pluralityof shims include an opening located at a side and extends to a fastenerslot disposed through the each of the plurality of shims, wherein theeach of the plurality of shims is located between the first clamp memberand the second clamp member.
 19. The clamp assembly of claim 11, whereinthe at least one shim has a uniform thickness.
 20. A clamp assembly foruse with a tonneau cover assembly, the clamp assembly comprising: afirst clamp member; a second clamp member located opposite the firstclamp member to form a space located therebetween; a clamp fastenerextended through the space between the first clamp member and the secondclamp member; and at least one shim located in the space between thefirst clamp member and the second clamp member; wherein at least aportion of the at least one shim is configured to fit between flanges ofa cargo box sidewall.